High Temperature Materials Research Group

The demand for environmentally and resources-friendly processes as well as higher efficiency in thermal plants and machinery requires an increase of operating temperatures. However, processes conducted at high temperatures and often in complex atmospheres lead to increasing demands on the high temperature corrosion resistance of the materials used. The main research objectives of the "high temperature materials" group at DFI are material analysis and development in the field of aggressive, high temperature environments. Within this research field, we focus on the development of metallic and ceramic protective coatings and innovative material systems appropriate for extremely aggressive service conditions (e.g. chlorine, sulphur, bromine, vanadium, and carbon-rich environments) and operation temperatures up to 1800 °C.

Diffusion Coatings

In order to produce such coatings, the material surface is enriched with protective elements by diffusion, which later prevent substrate corrosion during high temperature exposure

Methods: Pack cementation (in-pack, out-of-pack, slurry)
Protective coatings for a better oxidation resistance of materials at high temperature in environments rich in water vapour, typical for gasification and combustion atmospheres
Slurry-based coatings for application on-site in plants or on machine parts

Computational modelling of coatings and their lifetime

Computer simulation tools are used to predict the material behaviour during manufacturing as well as their lifetime during their operation at high temperatures

Modelling of layer growth and phase formation in the pack cementation process
Computer modelling of the influence of defects on the mechanical properties of thermal barrier coatings and oxide layers

High temperature light weight metals

The replacement of Ni-based alloys by lighter materials in aviation turbines can decrease the CO₂ emissions

Determination and extension of the existing operation limits of intermetallic systems such as titanium aluminides
Thermal barrier coatings for intermetallic titanium aluminides
New materials for a "Beyond Nickel-based Superalloys" approach: Silicides

Functional high temperature coatings

Providing high temperature protective coatings with additional properties such as self-cleaning, thermal insulation or improved aerodynamics can increase the quality and the efficiency of different engineering processes

Self-healing "shark skin" coatings for turbines
Foam-like ceramic thermal barrier coatings

"Minimally-invasive" high temperature corrosion protection

New developments show that a slight change in the chemical composition near the surface region of different materials induces a change in the reaction mechanisms and hence in their corrosion behaviour as well

Development of stable and protective alumina layers by using the halogen effect
Sn-modified surfaces for catalytic poisoning in metal dusting environments
Controlling chlorine corrosion by selective doping of coatings

Research for industry

The work group also shares its methods and experience with industry and offers professional support and advice regarding industrial material problems and their explanation